Method and apparatus for erecting and bottom sealing cartons

ABSTRACT

Flat carton blanks having front and rear pairs of side panels, each panel having an associated top and bottom flap, are stored on edge in a magazine. The endmost blank is fed from the magazine in its own plane to a folding station, thence to an erection station, and finally through a gluing station to a compression station. The folding station has upper and lower pivoted plows for folding the top and bottom flaps respectively to the same side of the plane defined by the flat carton blank. Certain of these flaps are subsequently folded back through this plane so that the flaps project from the carton in both directions. One of the bottom flaps is left folded to its &#39;&#39;&#39;&#39;wrong&#39;&#39;&#39;&#39; side and this particular flap is used to erect the carton at the erection station.

United States Patent 1 Barton July 31, 1973 METHOD AND APPARATUS FORERECTING AND BOTTOM SEALING CARTONS Inventor: Bruce H. Barton, SouthWindsor,

Conn.

Assignee: Emhart Corporation, Bloomfield,

Conn.

Filed: Nov. 1, 1971 Appl. No.: 194,642

U.S. Cl. 93/53 M, 933/53 R, 93/53 SD Int. Cl B311) 5/02 Field of Search93/53 M, 53 BF, 53 SD,

References Cited UNITED STATES PATENTS 7/1963 Salwasser et al. 93/53 R9/1971 Allen 93/53 R 1/1969 Pearson 93/53 SD X FOLDING 38 STATIONMAGAZINE Primary ExaminerAndrew R. Juhasz Assistant ExaminerJames F.Coan Attorney.|ohn C. Hilton et al.

[57] ABSTRACT Flat carton blanks having front and rear pairs of sidepanels, each panel having an associated top and bottom flap, are storedon edge in a magazine. The endmost blank is fed from the magazine in itsown plane to a folding station, thence to an erection station, andFinally through a gluing station to a compression station. The foldingstation has upper and lower pivoted plows for folding the top and bottomflaps respectively to the same side of the plane defined by the flatcarton blank. Certain of these flaps are subsequently folded backthrough this plane so that the flaps project from the carton in bothdirections. One of the bottom flaps is left folded to its wrong side andthis particular flap is used to erect the carton at the erectionstation.

19 Claims, 11 Drawing Figures GLUING STATION I28 ERECTION STATIONCOMPRESSION STATION PAIENIEU JUL3 1 ma SHEEI 1 [IF 7 PATENIED M3 1 SHEU3 OF 7 PATENIED 1 973 saw u or 1 m N QE PATENIED JUL3 1 I975 sum 1 or 7METHOD AND APPARATUS FOR ERECTING AND BOTTOM SEALING CARTONS SUMMARY OFINVENTION This invention relates to apparatus for erecting and bottomsealing cartons of the type having interconnected top flaps. Moreparticularly, an apparatus and method is disclosed, having particularusefulness for erecting such cartons, although the apparatus could beadapted for use in erecting conventional cartons from the flat. Thepurpose of the interconnected top flaps is to prevent such flaps frominterfering with subsequent filling of the carton. When the top flapshave been folded back against the sides of the carton blank, and thecarton blank subsequently expanded, these top flaps cannot protrudeoutwardly from the carton side walls but remain adjacent to the sidewalls or panels during the erection and subsequent filling of thecarton. These interconnected top flaps can be cut at some later time torelease them for gluing, after filling of the carton.

A method and apparatus is disclosed for erecting prefolded and prescoredcartons from the flat, said cartons having front and rear pairs of sidepanels connected to one another on common primary fold lines, and eachside panel having a top and a bottom flap connected to its associatedside panel on secondary fold lines. While the top flaps may beinterconnected as described above, all of these panels and flaps arearranged in a common plan when the carton is in its flat configuration.The flat cartons are stored in a magazine from which the endmost cartoncan be fed in its own plane to a folding station. At this foldingstation the bottom and top flaps are folded in the same direction, andthrough a substantial angle, out of the plane of the side panels so thatthe carton initially assumes a generally U-shaped configuration with thetop and bottom flaps comprising the legs of the U and side panelscomprising the base of the U. The top and bottom flaps of the front sidepanels are thereafter folded back through this plane and through asubstantial angle in the opposite direction to provide a carton whichhas a generally I- shaped cross section. However, at least one of thebottom flaps, associated with one of the front side panels, is left inits initially folded condition, that is to the wrong side, in order toprovide a convenient attachment point for mechanism for erecting thecarton. The carton is then fed to an erection station where thisparticular bottom flap is grasped by a vacuum device, and swung through90, about anaxis coincident with one of the primary fold lines of thecarton blank so as to erect the carton. The bottom flap associated withthe other front side panel, opposite the last mentioned bottom flap usedto erect the carton, is tucked under as the erected carton is again feddownstream. Glue is applied to the projecting bottom flaps assocaitedwith opposite side panels as the carton is fed through a glue station.The top flaps are interconnected, and will have been previously ploweddown adjacent the side panels and these top flaps remain in thisposition during the erection process as described above. The gluedbottom flaps are then folded inwardly under the bottom flaps or glue.The carton is thereby rendered ready for the filling process, with thetop flaps held in position by the interconnected top flaps describedabove.

The primary object of the present invention is to provide a method andapparatus for erecting and gluing up cartons of the type describedabove, which apparatus is capable of operating at relatively high speedsso as to handle cartons for loading in a modern bottling plant or thelike.

Another object of the present invention is to provide an improvedapparatus and method which takes peculiar advantage of quick settingglue by the application of pressure to the bottom flaps for only a shortperiod of time.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1, comprising FIGS. 1A and 1B, isan overall elevational view of the machine showing the magazine, thefolding station, the erection station, the gluing station and thecompression station with the drive means associated particularly withthe magazine the folding station erection station and the gluingstation.

FIG. 2, comprising FIGS. 2A and 2B, is an overall plan view of theapparatus shown in FIG. 1.

FIG. 3 is a schematic view of the configuration of the carton as itpasses through the machine, with certain carton engaging components ofthe apparatus being shown in schematic fashion.

FIG. 4 is a perspective view taken at the folding station illustratingthe configuration of the carton blank just prior to the foldingoperation.

FIG. 5 is a view similar to FIG. 4 illustrating the carton blank at aslightly latter instant of time, and

FIG. 6 is a view similar to FIGS. 4 and 5 illustrating the carton readyto leave the folding station.

FIG. 7 is a sectional view of the lower portion of the folding station.

DETAILED DESCRIPTION Turning now to the drawings in greater detail, FIG.3 best illustrates the overall functional concept of the machinecomponents. As shown in magazine is provided at one end of the machine,in which a plurality of carton blanks C, C are provided in stackedrelationship, being mounted on edge and supported by three feed screws10, 12 and 14. The feed screws move the carton blanks in the directionof the arrow 16, and also urge the carton blanks toward a fixed guide 18provided for this purpose at one side of the magazine.

Means is provided for rotating these leadscrews l0, l2 and 14, and asbest shown in FIG. 2A said means includes a series of belt drivensprockets, indicated generally at 20 arranged one on each of the farends of the lead screws 10, 12 and 14. The sprockets 20 are driven fromthe belt 22 which in turn is driven through a shaft 24, which shaft isin turn chain driven from a gear box 30, which gear box is in turndriven from the motor M. The gear box 30 also drives a chain 32associated with driving other components of the machine to be described.

As shown in FIGS. 1A and 3 an air cylinder 34 is provided with a device36 for stripping the endmost carton from the stack of cartons in themagazine so that each carton is entered between driven rolls, indicatedgenerally at 38, so as to be fired at relatively high speed against astop 41. These continuously driven rolls 38 are journalled at either endin fixed structure of the apparatus, and as best shown in FIG. 1A, drivemeans 42 is provided below the magazine for rotating said rolls.

The stop 41 for interripting downstream movement of the carton blank Ccomprises an air cylinder 41 which has its movable part adapted forextension into the path of movement of the flat blank. A cantileveredflight bar best shown in FIG. 2A is continuously driven so that it runsthrough an inactive portion of its cycle between the position shown inFIG. 3, and a position at the upstream edge of the carton at the foldingstation where it will then move through its active cycle to advance thecarton from the folding station to an erection station to be described.This flight bar 40 is shown in FIG. 2A at this upstream position, and issupported by two runs of two chain conveyors 44, 44 for movement in theactive direction, and for return movement out of the path of movement ofthe cartons.

Prior to describing the apparatus and means for folding the flaps of thecarton blank at the folding station, the configuration of the cartonblank itself will be discussed. The carton blank is of conventionalconstruction, and comprises a pair of front side panels, A and B, whichare intergrally connected to one another on a primary fold line 50preformed in the carton blank before it is inserted in the magazine. Twosimilar, but oppositely arranged rear side panels C and D, are providedon the back side of the prefolded carton blank, and these rear sidepanels C and D are also connected an associated primary fold line (notshown]. Further fold lines are provided between the front and. rear sidepanels, A and D respectively, and between the side panels B and C, andthese latter fold lines will be referred to as the leading and trailingedges respectively of the carton blank C shown at the folding station inFIG. 3.

Each of the side panels A, B, C and D has associated therewith a pair ofend flaps, which will be referred to herein as top and bottom flaps, Eand F respectively, for the side panel A, and top and bottom flaps G andH for the side panel B. Top and bottom flaps L and M are carried by theside panel D, and J and K for the side panel C. These top and bottomflaps, E through M inclusively, are connected to the associated sidepanels by secondary fold lines, as indicated generally at 52 and S4 forexample. Thus, the carton blanks are prefolded and prescored to permitthem to be readily erected for use. It should be noted that the topflaps E, G, J and L are connected to one another by interconnectingtabs, as indicated generally at 56, so as to keep these top flaps inposition during the erection process.

As mentioned above the cantilevered flight bar 40 is continuously drivenin the directions described above with reference to FIG. 2A, and saidbar 40 provides a means for advancing the carton from the foldingstation to the erection station. The carton is held at the foldingstation by fixed guide rails, best shown at 43 and 45 in FIG. 4., and isfolded into the configuration shown at 100 in FIG. 3 by carton foldingmeans, which means is best shown in FIGS. 4, 5 and 6 and serves to foldall of the top and bottom flaps, E through M, in the same generaldirection and through a substantial angle, preferably on the order of90, so that the initially flat carton assumes a generally U-shape assuggested in FIGS. 4 and 5, and more particularly so that upper andlower portions of the carton are bent respectively into generallyL-shaped configurations by upper and lower carton folding means, 60 and70 respectively.

The upper carton folding means 60 comprises a plow 61 mounted ondepending arms, 62 and 64, the upper ends of which arms are journaled ona rock shaft 66 best shown in FIG. 1A carried in the fixed frame of themachine and oscillated to and from, or through the positions shown inFIGS. 4, 5 and 6 to accomplish the desired motion of the plow 61. Theupper carton folding plow 61 is thus adapted for transverse movementacross the plane defined by the initially adjacent side panels A, B, Cand D of the flat carton blank, first in one direction, as shown in FIG.5, so as to fold all of the top flaps E, G, J and L in one direction,and to subsequently fold the top panels E and G, associated with thefront side panels A and B, back through the above described plane of theside panels as the plow 61 returns in the opposite direction as shown inFIGS. 5 and 6. More particularly, the plow 61 serves to fold all the topflaps E, G, .I and L rearwardly and a vacuum device 68 then grips thelowermost top flap J to hold it, and the other top flap L which isconnected thereto by means of the connecting tab 56, in the L-shapedconfiguration depicted in FIGS. 5 and 6. As the two top flaps G and Espring back toward their original vertical orientation, when the plow 61clears the ends thereof, return movement of said plow 61 serves tocontinue folding these flaps G and E toward the FIG. 6 position whereinthe carton blank assumes a generally I-shaped configuration with the topflaps projecting laterally outwardly from the plane of the side panelsA, B, C and D.

The vacuum device 68 comprises an evacuated chamber with a perforatedupper side wall which can be evacuated so as to hold the top flaps J andL in the position shown in FIGS. 5 and 6. The top flap folding means 60also includes an elongated L-shaped guide 63, which will continue tohold the top flaps J and L even when the evacuated chamber is vented toatmosphere prior to moving the carton downstream.

The bottom flaps, F, Hand K, M, are folded in a substantially similarfashion by the movable plow means 70, but for the fact that one bottomflap H is left folded to the wrong side in order to provide a convenientmeans for erecting the carton at the erection station. Moreparticularly, the lower plow means 70 is rotatably supported foroscillatory movement about a rock shaft (not shown) substantiallysimilar to the shaft 66 described above. The lower plow means comprisesa lower plow 71 supported by crank arms 72, 72 for movement about therock shaft axis from and to the positions shown in FIGS. 4 and 5. Theplow 71 is adapted to engage all of the bottom flaps and to move themfrom their initial position, shown in FIG. 4 to a generally L-shapedconfiguration wherein all of these bottom flaps project rearwardly at asubstantial angle. The plow 71 then moves past the free edges of thesebottom flaps, and a vacuum device 78 holds the-bottom flap M in the FIG.5 position while the bottom flap F springs back toward the vertical. Thevacuum device includes a fixed housing 78 provided with'a lower wallwhich is adapted to be selectively evacuated so as to support the bottomflap M associated with the rear side panels C and D in this foldedposition. A fixed lower guide 45 is provided for supporting the lowerportion of the carton blank during the folding movement of the lowerplow 71.

The lower plow means 70 also includes a second movable plow 75 supportedon an arm 76, which arm is in turn carried on a rock shaft (not shown)other than the rock shaft which carries the arms 72 and 74. Thus, thesecond plow 75 is adapted to being oscillated through an angulardisplacement which is retarded slightly with respect to the plow 71.This configuration allows all the bottom flaps to be folded initially bythe plow 71, including flaps H and K; but, as the plow 71 releases theseflaps by traveling past their free edges as described above, the secondplow 74 holds the lowermost bottom flap H and the adjacent flap K, asbest shown in FIG. 5, allowing only bottom flap F to be released asdescribed above. This second plow 74 remains in position for sosupporting bottom flaps H and K wile plow 71 returns to fold bottom flapF to the right side, as best shown in FIG. 6. The vacuum devices 68 and78 can now be released and the carton adequately supported for transferto the erection station. In this connection, it should be noted that theinitially flat carton blank is supported at the folding station on shelfmeans comprising a ledge 77 which ledge is itself movable as a result ofbeing carried on supports 79 welded to an L-shaped guide 73. The guidesurface 73 is similar to the guide 63 referred to above and supports thefolded bottom flaps as the blank leaves the folding station.

As mentioned above, the flight bar 40 serves to feed the carton blank,in the I-shaped configuration shown at 100 in FIG. 3, from the foldingstation to the erection station. At the erection station a fixedhousing, including a perforated bottom wall, is provided for engagingthe rear flap K of the carton blank in order to hold the carton blank inplace at the erection station. This vacuum device is shown generally at102 in FIG. 3. A fixed guide 104 is also provided at the erectionstation in conjunction with a pivoted guide 106, located in spacedgenerally parallel relation to the fixed guide 104, to fold thelaterally projecting top flaps E, G, J and L downwardly from theirprojecting positions, shown at 100, to positions where they overlie theoutsides of the side panels A, B, C and D respectively. The guide 104 isfixed in the frame of the machine, whereas the guide 106 is mounted on acrank arm structure 108, which crank arm structure is generally U-shapedin configuration including parallel links 110 and 114, and connectinglink 112 as best shown in FIGS., 1A and 2A. It should be noted that thelower crank arm 114 is journaled on a rock shaft 116, which rock shaftis adapted to being oscillated between the position shown in FIG. 3 andthat shown in FIGS. 1A and 2A, by mechanism, indicated generally at 118,in timed operation with other components of the machine. It is furthernoted that the axis of rotation of the rock shaft 116 is provided inaccurately aligned relationship with the trailing edge of the carton asdefined by the primary fold line which is the connection between theside panels B and C.

Still-with reference to the rock shaft 116 and to the lower crank arm114 associated therewith, vacuum means 120 is also provided on the crankarm 114 for grasping the bottom flap H from underneath so as to swingthis flap H about an axis coinciding with the primary fold line referredto above, and to erect the carton on the deadplate 122 provided for thispurpose at the erection station. The vacuum device 120 is provided withvacuum pressure when needed so as to engage the underside of the bottomflap H when a carton is positioned as shown in FIG. 3 and to swing thecarton from its partially folded condition, as there shown, to

its erected condition, as indicated generally at 1.22 in FIG. 3. Thedeadplate is provided with a cutout'l24 to give adequate clearance forthe U-shaped structure during this swinging movement of this vacuumdevice 120.

When the carton blank has been erected to the condition shown at 122 inFIG. 3, a flight bar 126, provided cantilevered fashion on the flightbar conveyor 128, will have arrived at a position for engaging the sidepanel B of the erected carton to advance said erected carton downstreamthrough the gluing station and finally to a compression station. As theerected carton moves across the deadplate the bottom flap M, associatedwith the side panel D of the carton, will be engaged by a flap tuckingdevice, indicated generally at 132 in FIGS. 1B and 2B. This flap tuckingdevice 132 includes a finger 134 which carries a cam follower operatedby a cam 136, so as to be raised and lowered in timed relationship withmovement of the'flight bar 126 and hence of the erected carton in orderto tuck the bottom flap M downwardly into a closed positioncorresponding to that of the bottom flap H. The said flap 1-1 will havebeen prepositioned as a result of erecting the case. The case at thegluing station in FIG. 3 is so configurated while the flap M night beleft in position for being prepositioned in the same manner as that ofthe flap H, it has been found that in erecting certain types of cartonsinterference results when both bottom flaps are prepositioned in thismanner, hence the requirement for the flap tucker 132.

Continued downstream movement of the erected carton through a gluingstation in timed operation with segmented glue rolls, indicatedgenerally at 138, causes strips of quick set glue or other adhesive tobe layed on the exposed underside of the unfolded bottom flaps F and K.Finally, fixed plows downstream of the gluding station are adapted toengage these projecting bottom flaps F and K to fold these glued bottomflaps downwardly and inwardly and then upwardly against the previouslyfolded bottom flaps H and M to provide an upwardly open backing case tothe compression station.

In the embodiment shown in FIGS. 1B and 2B, a compression station isprovided at the downstream end of the machine, at which station avertically reciprocable plunger 142, having a platform or the like atits lower end, and operated through a crank arm '144 through the aircylinder 146, is provided for compressing the bottom flaps against aplaten therebetween to set the adhesive. The plunger 142 dropsmomentarily into the upwardly open packing case after it has beendeposited on the platen, provided for this purpose at the downstream endof the machine, and after the flight bar 126 has relinquished control ofthe case. After the bottom flaps have been compressed the plunger israised, and the next succeeding case formed by the apparatus describedabove displaces the compressed case downstream on the ways 148 and theplunger 142 compresses the next succeeding case.

As described above the upwardly open packing case is thus convenientlyconfigured for filling, the interconnecting tabs 56, 56 holding the topflaps E, G, J and L in the position shown at 150 in FIG. 3 during thefilling operation. Once the case has been filled, these tabs can bereadily severed to allow the top flaps to be folded over the case in aconventional fashion.

I claim:

l. in an apparatus for erecting prefolded and prescored cartons from theflat, said cartons having front and rear pairs of side panels connectedto one another on common primary fold lines and each side panel having atop and a bottom flap also connected thereto on secondary fold lines,all of these panels and flaps being arranged in a common plane when saidcarton is in its flat configuration, the improvement comprising:

a. means for storing a stack of such flat cartons,

b. means for withdrawing the endmost carton from the stack and feedingit to a folding station,

0. lower carton folding means at said folding station for folding saidbottom flaps in the same direction and through a substantial angle sothat the initially flat carton assumes a generally L-shapedconfiguration,

d. means for retaining at least one of said bottom flaps in saidL-shaped configuration,

e. means for folding at least one other bottom flap back through theplane defined by said side panels and through a substantial angle in adirection opposite to that of said lower carton folding means,

f. means for feeding the partially folded carton from said foldingstation downstream to an erection station,

g. vacuum means for grasping at least one of the bottom flaps orientedat a substantial angle to the plane of said side panels, and

b. means for swinging said vacuum means about an axis coinciding withone of said primary fold lines to erect the carton.

2. In an apparatus for erecting prefolded and prescored cartons from theflat, said cartons having front and and rear pairs of side panelsconnected to one another on common primary fold lines and each sidepanel having a top and a bottom flap also connected thereto on secondaryfold lines, all of these panels and flaps being arranged in a commonplane when said carton is in its flat configuration, the improvementcomprising:

a. means for storing a stack of such flat cartons,

b. means for withdrawing the endmost carton from the stack and feedingit to a folding station,

c. lower carton folding means at said folding station for folding saidbottom flaps in the same direction and through a substantial angle sothat the initially flat carton assumes a generally L-shapedconfiguration,

d. means for retaining at least one of said bottom flaps in saidL-shaped configuration,

e. means for folding at least one other bottom flap back through theplane defined by said side panels and through a substantial angle in adirection opposite to that of said lower carton folding means,

f. upper carton folding means for folding said top flaps through asubstantial angle and in the same direction so that the initially flatcarton has an L- shaped configuration for its upper portion as well asfor its lower portion at said folding station,

g. means for retaining at least one of said top flaps in said L-shapedconfiguration,

h. means for folding at least one other top flap back through the planedefined by said side panels and through a substantial angle in adirection opposite to that of said upper carton folding means,

i. means for feeding the partially folded carton from said foldingstation downstream to an erection station,

j. a deadplate at said erection station for holding said bottom flaps intheir partially folded positions,

. k. top flap engaging means at said erection station for folding saidtop flaps downwardly against their associated side panels as saidpartially folded carton reaches said erection station.

3. The combination recited in claim 2 further characterized by vacuummeans for grasping at least one of the bottom flaps oriented at asubstantial angle to the plane of said side panels, and means forswinging said vacuum means about an axis coinciding with one of saidprimary fold lines to erect the carton on said deadplate.

4. In an apparatus for erecting prefolded and prescored cartons from theflat, said cartons having front and rear pairs of side panels connectedto one another on common primary fold lines and each side panel having atop and a bottom flap also connected thereto on secondary fold lines,all of these panels and flaps being arranged in a common plane when saidcarton is in its flat configuration, the improvement comprising:

a. means for storing a stack of such flat cartons,

b. means for withdrawing the endmost carton from the stack and feedingit to a folding station,

c. lower carton folding means at said folding station for folding saidbottom flaps in the same direction and through a substantial angle sothat the initially flat carton assumes a generally L-shapedconfiguration,

d. means for retaining at least one of said bottom flaps in saidL-shaped configuration,

e. means for folding at least one other bottom flap back through theplane defined by said side panels and through a substantial angle in adirection opposite to that of said lower carton folding means,

f. said lower carton folding means comprising lower plow means movabletransversely across the plane of said side panels in one direction pastthe free edges of said bottom flaps to first fold ail of said bottomflaps as aforesaid, and

g. said lower plow means having a second plow portion which is notmovable beyond at least one of said bottom flaps so as to hold said onebottom flap to said one side of said plane, and

h. said plow means causing at least one of said bottom flaps to returnin a direction opposite said one direction during return movement.

5. in an apparatus for erecting prefolded and prescored cartons from theflat, said cartons having from and rear pairs of side panels connectedto one another on common primary fold lines and each side panel having atop and a bottom flap also connected thereto on secondary fold lines,all of these panels and flaps being arranged in a common plane when saidcarton is in its flat configuration, the improvement'comprising:

a. means for storing a stack of such flat cartons,

b. means for withdrawing the endmost carton from the stack and feedingit to a folding station,

0. lower carton folding means at said folding station for folding saidbottom flaps in the same direction and through a substantial angle sothat the initially flat carton assumes a generally L-shapedconfiguration,

(1. means for retaining at least one of said bottom flaps in saidL-shaped configuration,

e. means for folding at least one other bottom flap back through theplane defined by said side panels and through a substantial angle in adirection opposite to that of said lower carton folding means,

f. upper carton folding means for folding said top flaps through asubstantial angle and in the same direction so that the initially flatcarton has an L- shaped configuration for its upper portion as well asfor its lower portion at said folding station,

g. means for retaining at least one of said top flaps in said L-shapedconfiguration,

h. means for folding at least one other top flap back through the planedefined by said side panels and through a substantial angle in adirection opposite to that of said upper carton folding means,

i. said lower carton folding means comprises lower plow means movabletransversely across the plane of said side panels in one direction pastthe free edges of said bottom flaps to first fold all of said bottomflaps as aforesaid, and

j. said lower plow means having a second plow portion which is notmovable beyond at least one of said bottom flaps so as to hold said onebottom flap to said one side of said plane, and

k. said plow means causing at least one of said bottom flaps to returnin a direction opposite said one direction during return movement.

6. The combination recited in claim wherein said upper carton foldingmeans comprises upper plow means movable transversely across the planeof said side panels in one direction to first fold all of said top flapsas aforesaid, and said upper plow means being movable beyond the freeedges of said top flaps so as to fold at least one of them back throughsaid plane when said upper plow means returns in a direction oppositesaid one direction.

7. The combination recited in claim 4 wherein said means for retainingat least one of said bottom flaps at said folding station comprises amovable shelf with an attached ledge for supporting the initially flatcarton blank as said blank enters the folding station, said shelfincluding a guide surface to support the folded bottom flap as thecarton leaves the folding station, and a housing with a lower wall whichcan be selectively evacuated to retain at least one bottom flap duringthe folding of said bottom flaps.

8. The combination recited in claim 6 wherein said means for retainingat least one of said bottom flaps at said folding station comprises afixed lower housing having a lower wall which can be selectivelyevacuated to retain at least one bottom flap, said means for retainingat least one of said top flaps at said folding station comprising afixed upper housing located generally above said lower housing, saidupper housing having an upper wall which is selectively evacuated toretain said one top flap at said folding station.

9. The combination recited in claim 8 further characterized by vacuummeans at said erection station for grasping said one from side panelbottom flap which is folded just below said rear side panel bottom flap,and means for swinging said vacuum means about an axis coinciding withone of said primary fold lines to erect the carton on said deadplate.

10. The combination recited in claim 9 further characterized by bottomflap tucking means located downstream of said erection station, andmeans for moving the erected carton from said erection station through aglue station downstream thereof, said tucking means serving to close thebottom flap opposite said one front side panel bottom flap as theerected carton moves from said erection station to said gluing station.

11. The combination recited in claim 10 wherein said glue stationcomprises segmented glue rolls arranged in spaced sets to apply stripsof glue to the underside of the remaining two projecting bottom flaps asthe erected carton is moved continuously through said glue station, andfixed plow means downstream of the glue station to fold said remainingtwo projecting bottom flaps and to form a bottom for the erected carton.

12. The combination recited in claim 8 wherein said second portion ofsaid lower carton folding means moves with said bottom flap folding plowin said one direction but trails said plow, and wherein said secondportion remains stationary at least momentarily to support said onebottom flap as aforesaid even as said plow returns in said oppositedirection to refold said at least one bottom flap as aforesaid.

13. A method for erecting prefolded and prescored cartons from the fiat,said cartons having front and rear pairs of side panels connected to oneanother on common primary fold lines and each side panel having a topand a bottom flap connected to its associated side panel on secondaryfold lines, all of these panels and flaps being arranged in a commonplane when the carton is in its flat configuration, said methodcomprising the successive steps of:

a. folding said bottom flaps in the same direction and through asubstantial angle out of the plane of said side panels so that a lowerportion of the initially flat carton assumes a generally L-shapedconfiguration, I

b. holding at least one of said bottom flaps in said L- shapedconfiguration,

c. folding at least one other bottom flap back through the plane definedby said side panels and through a substantial angle in a directionopposite said directon of folding referred to in step (a) above,

(1. grasping one of the bottom flaps oriented at a substantial angle tothe plane of said side panels, and

e. swinging the flap so grasped about an axis coincident with one ofsaid primary fold lines, through to erect the carton.

14. A method for erecting prefolded and prescored cartons from the flat,said cartons having front and rear pairs of side panels connected to oneanother on common primary fold lines and each side panel having a topand a bottom flap connected to its associated side panel on secondaryfold lines, all of these panels and flaps being arranged in a commonplane when the carton is in its fiat configuration, said methodcomprising the successive steps of:

a. folding said bottom flaps in the same direction and through asubstantial angle out of the plane of said side panels so that a lowerportion of the initially flat carton assumes a generally L-shapedconfiguration,

b. holding at least one of said bottom flaps in said L- shapedconfiguration,

0. folding at least one other bottom flap back through the plane definedby said side panels and through a substantial angle in a directionopposite said direction of folding referred to in step (a) above,

d. folding the top flaps through a substantial angle and in the samedirection so that an upper portion of the initially flat carton assumesan L-shaped configuration,

e. holding at least one of said top flaps in said L- shapedconfiguration,

f. folding at least one other top flap back through the plane defined bysaid side panel and through a substantial angle in a direction oppositesaid direction referred to in step (d) above,

g. grasping one of the bottom flaps oriented at a substantial angle tothe plane of said side panels, and

h. swinging the flap so grasped about an axis coincident with one ofsaid primary fold lines, through 90,to erect the carton.

15. In an apparatus for erecting prefolded and prescored cartons fromthe flat, said cartons having from and rear pairs of side panelsconnected to one another on common primary fold lines and each sidepanel having a top and a bottom flap also connected thereto on secondaryfold lines, all of these panels and flaps being arranged in a commonplane when said carton is in its flat configuration, the improvementcomprising:

a. means for storing a stack of such flat cartons,

b. means for withdrawing the endmost carton from the stack and feedingit to a folding station,

c. lower carton folding means at said folding station for folding saidbottom flaps in the same direction and through a substantial angle sothat the intially flat carton assumes a generally L-shapedconfiguration,

d. means for retaining at least one of said bottom flaps in saidL-shaped configuration,

e. means for folding at least one other bottom flap back through theplane defined by said side panels and through a substantial angle in adirection opposite to that of said lower carton folding means,

f. means for feeding the partially folded carton from said foldingstation downstream to an erection station,

g. means for holding one of said rear panels and its associated bottomflap at said erection station, and

h. means for swinging one of said front panels and its associated bottomflap on an axis coincident with one of said primary fold lines to erectthe carton.

16. The combination recited in claim 15 further characterized by adeadplate at said erection station for holding said bottom flaps intheir partially folded positions during said swinging motion of saidfront panel and its associated bottom flap.

17. The combination recited in claim 16 further characterized by bottomflap tucking means located downstream of said erection station, andmeans for moving the erected carton from said erection station through aglue station downstream thereof, said tucking means serving to close thebottom flap opposite said one front side panel bottom flap as theerected carton moves from said erection station to said gluing'station.

18. The combination recited in claim 17 wherein said glue stationcomprises segmented glue rolls arranged in spaced sets to apply stripsof glue to the underside of the remaining two projecting bottom flaps asthe erected carton is moved continuously through said glue station, andfixed plow means downstream of the glue station to fold said remainingtwo projecting bottom flaps and to form a bottom for the erected carton.

19. A method for erecting prefolded and prescored cartons from the flat,said cartons having front and rear pairs of side panels connected to oneanother on common primary fold lines and each side panel having a topand a bottom flap connected to its associated side panel on secondaryfold lines, allof these panels and flaps being arranged in a commonplane when the carton is in its fiat configuration, said methodcomprising the successive steps of:

a. folding said bottom flaps in the same direction and through asubstantial angle out of the plane of said side panels so that a lowerportion of the initially flat carton assumes a generally L-shapedconfiguration,

b. holding at least one of said bottom flaps in said L- shapedconfiguration,

c. folding at least one other bottom flap back through the plane definedby said side panels and through a substantial angle in a directionopposite said direction of folding referred to in step (a) above,

d. holding one of said rear panels and its associated bottom flap,

e. swinging one of said front panels and its associated bottom flap onan axis coincident with one of said primary fold lines to erect thecarton.

Patent No. I

fiERTEFiCATE GE? CQERECTIGN.

Dated Jul 31 1973 Inventor(s) Bruce H. Barton It is certified that errorappears in tHebove-identified patent and that said Letters-Patent arehereby corrected as shown below:

Col.

Col.

line 51, "assocaited" should be --ass ociated-- libel}, "interripting"should be --interrupting--.

iihe 13, 'wile" shouldbe -whi1e--.i .v

line 25 "night" should be --I night--.

line 37, "gludi'rig" should be "gluin Q "backing" should be packing--line 41,

Signed and sealed this 25th day of December 1973.

(SEAL) Attest:

EDWARD M.FLETCHEIR,JR. Attesting Officer RENE D. TEGTD EYER ActingCommissioner of Patents

1. In an apparatus for erecting prefolded and prescored cartons from theflat, said cartons having front and rear pairs of side panels connectedto one another on common primary fold lines and each side panel having atop and a bottom flap also connected thereto on secondary fold lines,all of these panels and flaps being arranged in a common plane when saidcarton is in its flat configuration, the improvement comprising: a.means for storing a stack of such flat cartons, b. means for withdrawingthe endmost carton from the stack and feeding it to a folding station,c. lower carton folding means at said folding station for folding saidbottom flaps in the same direction and through a substantial angle sothat the initially flat carton assumes a generally L-shapedconfiguration, d. means for retaining at least one of said bottom flapsin said L-shaped configuration, e. means for folding at least one otherbottom flap back through the plane defined by said side panels andthrough a substantial angle in a direction opposite to that of saidlower carton folding means, f. means for feeding the partially foldedcarton from said folding station downstream to an erection station, g.vacuum means for grasping at least one of the bottom flaps oriented at asubstantial angle to the plane of said side panels, and h. means forswinging said vacuum means about an axis coinciding with one of saidprimary fold lines to erect the carton.
 2. In an apparatus for erectingprefolded and prescored cartons from the flat, said cartons having frontand and rear pairs of side panels connected to one another on commonprimary fold lines and each side panel having a top and a bottom flapalso connected thereto on secondary fold lines, all of these panels andflaps being arranged in a common plane when said carton is in its flatconfiguration, the improvement comprising: a. means for storing a stackof such flat cartons, b. means for withdrawing the endmost carton fromthe stack and feeding it to a folding station, c. lower carton foldingmeans at said folding station for folding said bottom flaps in the samedirection and through a substantial angle so that the initially flatcarton assumes a generally L-shaped configuration, d. means forretaining at least one of said bottom flaps in said L-shapedconfiguration, e. means for folding at least one other bottom flap backthrough the plane defined by said side panels and through a substantialangle in a direction opposite to that of said lower carton foldingmeans, f. upper carton folding means for folding said top flaps througha substantial angle and in the same direction so that the initially flatcarton has an L-shaped configuration for its upper portion as well asfor its lower portion at said folding station, g. means for retaining atleast one of said top flaps in said L-shaped configuration, h. means forfolding at least one other top flap back through the plane defined bysaid side panels and through a substantial angle in a direction oppositeto that of said upper carton folding means, i. means for feeding thepartially folded carton from said folding station downstream to anerection station, j. a deadplate at said erection station for holdingsaid bottom flaps in their partially folded positions, k. top flapengaging means at said erection station for folding said top flapsdownwardly against their associated side panels as said partially foldedcarton reaches said erection station.
 3. The combination recited inclaim 2 further characterized by vacuum means for grasping at least oneof the bottom flaps oriented at a substantial angle to the plane of saidside panels, and means for swinging said vacuum means about an axiscoinciding with one of said primary fold lines to erect the carton onsaid deadplate.
 4. In an apparatus for erecting prefolded and prescoredcartons from the flat, said cartons having front and rear pairs of sidepanels connected to one another on common primary fold lines and eachside panel having a top and a bottom flap also connected thereto onsecondary fold lines, all of these panels and flaps being arranged in acommon plane when said carton is in its flat configuration, theimprovement comprising: a. means for storing a stack of such flatcartons, b. means for withdrawing the endmost carton from the stack andfeeding it to a folding station, c. lower carton folding means at saidfolding station for folding said bottom flaps in the same direction andthrough a substantial angle so that the initially flat carton assumes agenerally L-shaped configuration, d. means for retaining at least one ofsaid bottom flaps in said L-shaped configuration, e. means for foldingat least one other bottom flap back through the plane defined by saidside panels and through a substantial angle in a direction opposite tothat of said lower carton folding means, f. said lower carton foldingmeans comprising lower plow means movable transversely across the planeof said side panels in one direction past the free edges of said bottomflaps to first fold all of said bottom flaps as aforesaid, and g. saidlower plow means having a second plow portion which is not movablebeyond at least one of said bottom flaps so as to hold said one bottomflap to said one side of said plane, and h. said plow means causing atleast one of said bottom flaps to return in a direction opposite saidone direction during return movement.
 5. In an apparatus for erectingprefolded and prescored cartons from the flat, said cartons having frontand rear pairs of side panels connected to one another on common primaryfold lines and each side panel having a top and a bottom flap alsoconnected thereto on secondary fold lines, all of these panels and flapsbeing arranged in a common plane when said carton is in its flatconfiguration, the improvement comprising: a. means for storing a stackof such flat cartons, b. means for withdrawing the endmost carton fromthe stack and feeding it to a folding station, c. lower carton foldingmeans at said folding station for folding said bottom flaps in the samedirection and through a substantial angle so that the initially flatcarton assumes a generally L-shaped configuration, d. means forretaining at least one of said bottom flaps in said L-shapedconfiguration, e. means for folding at least one other bottom flap backthrough the plane defined by said side panels and through a substantialangle in a direction opposite to that of said lower carton foldingmeans, f. upper carton folding means for folding said top flaps througha substantial angle and in the same direction so that the initially flatcarton has an L-shaped configuration for its upper portion as well asfor its lower portion at said folding station, g. means for retaining atleast one of said top flaps in said L-shaped configuration, h. means forfolding at least one other top flap back through the plane defined bysaid side panels and through a substantial angle in a direction oppositeto that of said upper carton folding means, i. said lower carton foldingmeans comprises lower plow means movable transversely across the planeof said side panels in one direction past the free edges of said bottomflaps to first fold all of said bottom flaps as aforesaid, and j. saidlower plow means having a second plow portion which is not movablebeyond at least one of said bottom flaps so as to hold said one bottomflap to said one side of said plane, and k. said plow means causing atleast one of said bottom flaps to return in a direction opposite saidone direction during return movement.
 6. The combination recited inclaim 5 wherein said upper carton folding means comprises upper plowmeans movable transversely across the plane of said side panels in onedirection to first fold all of said top flaps as aforesaid, and saidupper plow means being movable beyond the free edges of said top flapsso as to fold at least one of them back through said plane when saidupper plow means returns in a direction opposite said one direction. 7.The combination recited in claim 4 wherein said means for retaining atleast one of said bottom flaps at said folding station comprises amovable shelf with an attached ledge for supporting the initially flatcarton blank as said blank enters the folding station, said shelfincluding a guide surface to support the folded bottom flap as thecarton leaves the folding station, and a housing with a lower wall whichcan be selectively evacuated to retain at least one bottom flap duringthe folding of said bottom flaps.
 8. The combination recited in claim 6wherein said means for retaining at least one of said bottom flaps atsaid folding station comprises a fixed lower housing having a lower wallwhich can be selectively evacuated to retain at least one bottom flap,said means for retaining at least one of said top flaps at said foldingstation comprising a fixed upper housing located generally above saidlower housing, said upper housing having an upper wall which isselectively evacuated to retain said one top flap at said foldingstation.
 9. The combination recited in claim 8 further characterized byvacuum means at said erection station for grasping said one front sidepanel bottom flap which is folded just below said rear side panel bottomflap, and means for swinging said vacuum means about an axis coincidingwith one of said primary fold lines to erect the carton on saiddeadplate.
 10. The Combination recited in claim 9 further characterizedby bottom flap tucking means located downstream of said erectionstation, and means for moving the erected carton from said erectionstation through a glue station downstream thereof, said tucking meansserving to close the bottom flap opposite said one front side panelbottom flap as the erected carton moves from said erection station tosaid gluing station.
 11. The combination recited in claim 10 whereinsaid glue station comprises segmented glue rolls arranged in spaced setsto apply strips of glue to the underside of the remaining two projectingbottom flaps as the erected carton is moved continuously through saidglue station, and fixed plow means downstream of the glue station tofold said remaining two projecting bottom flaps and to form a bottom forthe erected carton.
 12. The combination recited in claim 8 wherein saidsecond portion of said lower carton folding means moves with said bottomflap folding plow in said one direction but trails said plow, andwherein said second portion remains stationary at least momentarily tosupport said one bottom flap as aforesaid even as said plow returns insaid opposite direction to refold said at least one bottom flap asaforesaid.
 13. A method for erecting prefolded and prescored cartonsfrom the flat, said cartons having front and rear pairs of side panelsconnected to one another on common primary fold lines and each sidepanel having a top and a bottom flap connected to its associated sidepanel on secondary fold lines, all of these panels and flaps beingarranged in a common plane when the carton is in its flat configuration,said method comprising the successive steps of: a. folding said bottomflaps in the same direction and through a substantial angle out of theplane of said side panels so that a lower portion of the initially flatcarton assumes a generally L-shaped configuration, b. holding at leastone of said bottom flaps in said L-shaped configuration, c. folding atleast one other bottom flap back through the plane defined by said sidepanels and through a substantial angle in a direction opposite saiddirecton of folding referred to in step (a) above, d. grasping one ofthe bottom flaps oriented at a substantial angle to the plane of saidside panels, and e. swinging the flap so grasped about an axiscoincident with one of said primary fold lines, through 90*, to erectthe carton.
 14. A method for erecting prefolded and prescored cartonsfrom the flat, said cartons having front and rear pairs of side panelsconnected to one another on common primary fold lines and each sidepanel having a top and a bottom flap connected to its associated sidepanel on secondary fold lines, all of these panels and flaps beingarranged in a common plane when the carton is in its flat configuration,said method comprising the successive steps of: a. folding said bottomflaps in the same direction and through a substantial angle out of theplane of said side panels so that a lower portion of the initially flatcarton assumes a generally L-shaped configuration, b. holding at leastone of said bottom flaps in said L-shaped configuration, c. folding atleast one other bottom flap back through the plane defined by said sidepanels and through a substantial angle in a direction opposite saiddirection of folding referred to in step (a) above, d. folding the topflaps through a substantial angle and in the same direction so that anupper portion of the initially flat carton assumes an L-shapedconfiguration, e. holding at least one of said top flaps in saidL-shaped configuration, f. folding at least one other top flap backthrough the plane defined by said side panel and through a substantialangle in a direction opposite said direction referred to in step (d)above, g. grasping one of the bottom flaps oriented at a substantialangle to the plane of said side panels, and h. swinginG the flap sograsped about an axis coincident with one of said primary fold lines,through 90*, to erect the carton.
 15. In an apparatus for erectingprefolded and prescored cartons from the flat, said cartons having frontand rear pairs of side panels connected to one another on common primaryfold lines and each side panel having a top and a bottom flap alsoconnected thereto on secondary fold lines, all of these panels and flapsbeing arranged in a common plane when said carton is in its flatconfiguration, the improvement comprising: a. means for storing a stackof such flat cartons, b. means for withdrawing the endmost carton fromthe stack and feeding it to a folding station, c. lower carton foldingmeans at said folding station for folding said bottom flaps in the samedirection and through a substantial angle so that the intially flatcarton assumes a generally L-shaped configuration, d. means forretaining at least one of said bottom flaps in said L-shapedconfiguration, e. means for folding at least one other bottom flap backthrough the plane defined by said side panels and through a substantialangle in a direction opposite to that of said lower carton foldingmeans, f. means for feeding the partially folded carton from saidfolding station downstream to an erection station, g. means for holdingone of said rear panels and its associated bottom flap at said erectionstation, and h. means for swinging one of said front panels and itsassociated bottom flap on an axis coincident with one of said primaryfold lines to erect the carton.
 16. The combination recited in claim 15further characterized by a deadplate at said erection station forholding said bottom flaps in their partially folded positions duringsaid swinging motion of said front panel and its associated bottom flap.17. The combination recited in claim 16 further characterized by bottomflap tucking means located downstream of said erection station, andmeans for moving the erected carton from said erection station through aglue station downstream thereof, said tucking means serving to close thebottom flap opposite said one front side panel bottom flap as theerected carton moves from said erection station to said gluing station.18. The combination recited in claim 17 wherein said glue stationcomprises segmented glue rolls arranged in spaced sets to apply stripsof glue to the underside of the remaining two projecting bottom flaps asthe erected carton is moved continuously through said glue station, andfixed plow means downstream of the glue station to fold said remainingtwo projecting bottom flaps and to form a bottom for the erected carton.19. A method for erecting prefolded and prescored cartons from the flat,said cartons having front and rear pairs of side panels connected to oneanother on common primary fold lines and each side panel having a topand a bottom flap connected to its associated side panel on secondaryfold lines, all of these panels and flaps being arranged in a commonplane when the carton is in its flat configuration, said methodcomprising the successive steps of: a. folding said bottom flaps in thesame direction and through a substantial angle out of the plane of saidside panels so that a lower portion of the initially flat carton assumesa generally L-shaped configuration, b. holding at least one of saidbottom flaps in said L-shaped configuration, c. folding at least oneother bottom flap back through the plane defined by said side panels andthrough a substantial angle in a direction opposite said direction offolding referred to in step (a) above, d. holding one of said rearpanels and its associated bottom flap, e. swinging one of said frontpanels and its associated bottom flap on an axis coincident with one ofsaid primary fold lines to erect the carton.